FM2402R INTRODUCTION To the owner or user: The service manual you are reading is intended to provide you, and the maintenance or service technician, with the information needed to install, start up, clean, maintain, and service this ice system. The FM2402R is a remote condenser modular ice system. It features: front service for the freezer, gearmotor, control box, water reservoir, and bin control; an electronic circuit for monitoring ice and water level; a thermostatic expansion valve; and R-22 as the refrigerant. TABLE OF CONTENTS For the Installer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remote Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 For the Plumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 For the Electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Maintenance & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Removal and Replacement Water Reservoir & Bin Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Thrust Bearing & Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Water Seal Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Gearmotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Circuit Board Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Parts Lists and Wiring Diagrams are located in the center of this manual, printed on yellow paper. December, 1992 Page 1 FM2402R FOR THE INSTALLER The FM2402R is designed to fit the following Scotsman storage bins: · B90 and extentions, with bin top KBT18. · BH800 no bin top needed. · BH900 using bin top KBT14. When installing a new system, check to be sure that you have everything you need before beginning: · Correct Bin · Correct Ice Machine · Correct Bin Top · All kits, legs, and information required for the specific job. TOP VIEW Allow 6" of space behind the machine for utility connections. 18.28" Ice Chute 6.7" x 6.2" 13.84" 34.84" BACK VIEW Liquid Line Connection (right system) 21" 3.1" Discharge Line Connection (left system) Allow 6" above machine for service. There are two separate ice making and refrigeration systems in this model. The liquid and discharge lines from each system must go to separate circuits in one remote condenser (RC1222). 15.53" 3.1" 20.84" 5.25" 4.5" 9.43" 3" Remote Condenser Junction Box Electrical Inlet Water Inlet 3/8" Flare Drain 3/4" FPT 17.8" 18.8" 21.66" SPECIFICATIONS: ICEMAKER Model Number FM2402RE-32A FM2402RE-3A Dimensions (w/o bin) HXWXD 27" x 42" x 24" same Basic Electrical 208-230/60/1 208-230/60/3 Ice Type FLAKE same Cond. Type R/Air R/Air * The Standard Finish is Enamel - Sandalwood. There is an optional stainless steel panel kit, SPKFM42 available to convert the unit to Stainless Steel. It is field installed. December, 1992 Page 2 FM2402R FOR THE INSTALLER Installation Limitations: This ice system is designed to be installed indoors, in a controlled environment: Min Max 0 1000F Air Temperature 50 F (Not including the remote condenser) 1000F Water Temperature 400F Water Pressure 20 PSIG 80 PSIG Voltage -5% +10% (Compared to the nameplate) Operating the machine outside of the limitations is misuse and can void the warranty. Water Limitations: An ice machine is a food manufacturing plant; it takes a raw material, water, and turns it into a food product, ice. The purity of the water is very important in obtaining pure ice and in maximizing product life. This is not intended as a complete resource for water related questions, but it does offer these general recommendations: 1. Check with a water treatment specialist for a water test, and recommendations regarding filters and treatment. 2. In most cases, the water used to make ice should be filtered or treated, depending upon the water. There is no one type of water filter that will be effective in all situations. That is why a water test is important. Scotsman Ice Systems are designed and manufactured with the highest regard for safety and performance. They meet or exceed the standards of UL, NSF, and CSA. Scotsman assumes no liability or responsibility of any kind for products manufactured by Scotsman that have been altered in any way, including the use of any part and/or other components not specifically approved by Scotsman. Scotsman reserves the right to make design changes and/or improvements at any time. Specifications and design are subject to change without notice. Typical Storage Bin - B90 1.25" December, 1992 Page 3 21.12" Drain 3/4" FPT FM2402R REMOTE CONDENSER SPECIFICATIONS 1/2" MALE QUICK CONNECT COUPLING FOR USE WITH R22625 OR RT2240 PRECHARGED LINE SET 22" 5.75" 19.86" 27.81" 3.5" 6.5" 7.5" 5.38" 32.56" 1.9" 5.0" LIQUID LINE 3/8" MALE QUICK CONNECT COUPLING FOR USE WITH RT2225 OR RT2240 PRECHARGED LINE SET MODEL DIMENSIONS H" X W" X D" 27.8" X 22 X 37.94" USE WITH MINIMUM CIRC. AMPACITY+ 2 BASIC ELECTRICAL 208-230/60/1 RC1222 1 FM2402R +Included with the icemakers minimum circuit ampacity. Use this value to determine wire size between icemaker and fan motor. RT-2225 Precharged line set, 25', R-22 - 2 required. Or: RT-2240. Precharged line set, 40', R-22 - 2 required. ICEMAKER NAMEPLATE LOCATED ON BACK PANEL SERIAL PLATE LOCATED BEHIND FRONT PANEL December, 1992 Page 4 FM2402R FOR THE INSTALLER Location Typical Storage Bin with Extension and Bin Top After uncrating and inspection, the unit is ready for installation. It is important that the machine be installed in a location where it has enough space around it to be accessible for service, usually a minimum of 6 inches. Try to avoid hot, dirty and crowded locations. Be sure that the location for the machine is within the limitations described on page 3. Storage Bin Tip the storage bin on its back, using parts of the carton to protect the exterior finish. Install the legs into the threaded holes in the bottom of the bin. Turn the leg levelers all the way in preparation for leveling later. Return the bin to the upright position, remove paper covering the bin gasket. Install the bin top according to the directions with the bin top. Note: Do not push bin into position, but lift it there. Pushing a bin, especially one with ice in it, can cause damage to the legs and the leg mounts. Ice Maker The machine is heavy, so the use of a mechanical lift is recommended for lifting the machine high enough to install on top of the bin. After the unit is placed on the bin, line it up so it is even with the back side. Secure the machine to the bin with the hardware provided with the machine. Remove the front panel and remove any shipping blocks. Note: Be sure to allow a 6" minimum space above the top of the machine for service. December, 1992 Page 5 FM2402R FOR THE INSTALLER: Remote Condenser Location Limited to a 40 foot or a 25 foot length of precharged refrigerant tubing connecting the icemaker to the remote condenser. The condenser must be above or level with the icemaker. Select the best available location, protecting the condenser from extremes of dirt, dust, and sun. Meet all applicable building codes. Usually the services of a licensed electrician are required. Roof Attachment 1. Install and attach the remote condenser to the roof of the building, using the methods and practices of construction that conform to the local building codes, including having a roofing contractor secure the condenser to the roof. 2. Have an electrician connect the remote condenser fan motor to the icemaker, using the junction box at the back of the icemaker. PRECHARGED LINE ROUTING CAUTION Do not connect precharged tubing until all routing and forming of the tubing is complete. See the coupling instructions for connecting instructions. 1. Each set of precharged refrigerant lines (either 25 foot or 40 foot) consists of a 3/8 inch diameter liquid line and a 1/2 inch diameter discharge line. Both ends of each line have quick connect couplings, one end has a schrader valve connection, that end goes to the condenser. Note: The openings in the building ceiling or wall, listed in the next step, are the minimum sizes recommended for passing the refrigerant lines through. 2. Have the roofing contractor cut a minimum hole for the refrigerant lines of 1 3/4 inch. Check local codes, a separate hole may be required for the electrical power to the condenser. CAUTION DO NOT KINK OR CRIMP REFRIGERANT TUBING WHEN INSTALLING IT. 3. Route the refrigerant lines through the roof opening. Follow straight line routing whenever possible. Any excess tubing MUST be retained within the building. 4. Spiral the excess length of pre charged tubing inside the building. Use a horizontal spiral (as illustrated) to avoid any traps in the lines. 5. Have the roofing contractor seal the holes in the roof per local codes. Note: Tight spiral shown is not required, bend tubing to a practical radius. Refrigerant charge is in the ice maker. Only a holding charge is in the "pre-charged" lines. REMOTE CONDENSER SPIRAL EXCESS TUBING INSIDE BUILDING LOCATE REMOTE CONDENSER ABOVE ICEMAKER December, 1992 Page 6 FM2402R FOR THE INSTALLER: Precharged Lines COUPLING INSTRUCTIONS CAUTION The couplings on the sets of precharged lines are self sealing when installed properly. Carefully follow the instructions: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. · Connect the 3/8 inch liquid line (schrader valve end) to the remote condenser fitting marked "liquid line". · Connect the other end of the liquid line to the icemaker fitting marked "liquid line." · Connect the 1/2 inch discharge line (schrader valve end) to the remote condenser fitting marked "discharge line". · Connect the other end of the liquid line to the icemaker fitting marked "discharge line". 3. Begin tightening the couplings together by hand, then using two wrenches (it is important that ONLY the nut on the precharged lines be turned, the other parts of the couplings must NOT be allowed to turn or the process will tear out the diaphragms and they will be loose in the refrigeration system) tighten the coupling until it bottoms out or a definite increase in resistance is felt. SERVICE PORTS REMOTE CONDENSER 4. Using a marker or pen, mark a line lengthwise from the coupling union nut to the bulkhead. Then tighten the coupling and additional 1/4 turn. As the nut turns, the line will show when 1/4 turn is made. 5. After all connections are made, and after the king valve has been opened, check the couplings for leaks. 3/8" LIQUID LINE 1/2" DISCHARGE LINE 3/8" LIQUID LINE 1/2" DISCHARGE LINE SCHRADER VALVE NO SCHRADER VALVE TO REMOTE CONDENSER TO ICEMAKER December, 1992 Page 7 FM2402R FOR THE INSTALLER: Location REMOTE CONDENSER ROOF CUTAWAY CONTACT ROOFING CONTRACTOR EXCESS PRECHARGED TUBING INSIDE BUILDING ICEMAKER SERVICE ACCESS SERVICE ACCESS SIDE AND BACK WALL CUTAWAY December, 1992 Page 8 FM2402R FOR THE PLUMBER CONFORM TO ALL APPLICABLE CODES Water Inlet WATER INLET 3/8" MALE FLARE FIELD SUPPLIED WATER FILTER HAND SHUT OFF VALVE CONNECT TO COLD WATER The recommended water supply is cold water. Use 3/8" O.D. copper tubing, connect to the 3/8" male flare at the back of the cabinet. Install a hand valve near the machine to control the water supply. Drains There is one 3/4" FPT drain at the back of the cabinet, the drain line is of the gravity type, and 1/4 inch per foot fall is an acceptable pitch for the drain tubing. There should be a vent at the highest point of the drain line, and the ideal drain receptacle would be a trapped and vented floor drain. Use only 3/4" rigid tubing. Storage Bin: A separate gravity type drain needs to be run. Insulation of this drain line i ...